System and method for continuous online safety and reliability monitoring

ABSTRACT

A system and method for continuous online safety and reliability monitoring is disclosed. The method includes the steps of obtaining operating information about at least one of a plurality of instrumented function components, which are part of an instrumented function, and determining a probability of failure on demand for the instrumented function based on the operating information. In variations, instantaneous probability of failure on demand, online mean time to failure (MTTF), and online safety integrity level (SIL) are also calculated for an instrumented function. In other variations of the invention, alarms are reported to an operator based on the variance indicating the probability of failure on demand for the instrumented function is too high. In yet further variations, the system allows a user to predict probability of failure on demand values into the future based on hypothetical and/or future planned test times.

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application Ser. No. 60/491,999 filed Aug. 1, 2003,entitled: SYSTEM AND METHOD FOR CONTINUOUS ONLINE SAFETY AND RELIABILITYMONITORING, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to control and monitoringsystems, and more specifically to industrial safety and reliabilitycontrol and monitoring systems.

2. Discussion of the Related Art

Modern industrial systems and processes tend to be technically complex,involve substantial energies and monetary interests, and have thepotential to inflict serious harm to persons or property during anaccident. Although absolute protection may not be possible to achieve,risk can be reduced to an acceptable level using various methods toincrease an industrial system's safety and reliability and mitigate harmif an event, e.g., a failure, does occur.

In the context of safety systems, one of these methods includesutilization of one or more safety instrumented systems (SIS). A safetyinstrumented system (SIS) is an instrumented system used to implementone or more safety instrumented functions (SIF), and is composed ofsensors, logic solvers and final elements designed for the purposes of:taking an industrial process to a safe state when specified conditionsare violated; permitting a process to move forward in a safe manner whenspecified conditions allow (permissive functions); and/or taking actionto mitigate the consequences of an industrial hazard.

A safety instrumented function (SIF) is a function implemented by a SIS,which is intended to achieve or maintain a safe state for a process withrespect to a specific event, e.g., a hazardous event. Hardware to carryout the SIF typically includes a logic solver and a collection ofsensors and actuators for detecting and reacting to events,respectively.

To direct appropriate design and planned maintenance of a SIF, safetystandards bodies have established a system that defines several SafetyIntegrity Levels (SIL) that are appropriate for a SIF depending upon theconsequences of the SIF failing on demand. According to theInternational Electrotechnical Commision (IEC) standard 61508, safetyintegrity level (SIL) is a measure of the risk reduction provided by aSIF based on four discrete levels, each representing an order ofmagnitude of risk reduction. As shown in Table 1, each SIL level isassociated with a designed average probability of failure on demand(PFD). For example, a SIL 1 means that the maximum probability offailure is 10% (i.e., the SIF is at least 90% available), and a SIL 4means that the maximum probability of failure is 0.01% (i.e., the SIF isat least 99.99% available). TABLE 1 DEMAND MODE OF OPERATION TargetAverage Safety Integrity Probability of Failure Level (SIL) on DemandTarget Risk Reduction 4 ≧10⁻⁵ to <10⁻⁴ >10,000 to ≦100,000 3 ≧10⁻⁴ to<10⁻³   >1000 to ≦10,000 2 ≧10⁻³ to <10⁻²   >100 to 1000 1 ≧10⁻² to<10⁻¹    >10 to ≦100

For continuous or high demand mode of operation, the following Table 2applies: TABLE 2 CONTINUOUS MODE OF OPERATION Target Frequency ofDangerous Failures to perform the Safety integrity safety instrumentedfunction Level (per hour) 4 ≧10⁻⁹ to <10⁻⁸ 3 ≧10⁻⁸ to <10⁻⁷ 2 ≧10⁻⁷ to<10⁻⁶ 1 ≧10⁻⁶ to <10⁻⁵

Consistent with existing, standardized methodology, during design of asafety instrumented system (SIS), safety integrity level (SIL)requirements are established for each SIF based upon the impact of thespecific hazardous event that the SIF is intended to prevent. Forexample, a SIL level of 1 may be assigned to a hazardous event thatimparts only minor property damage, whereas a SIL of 4 may be assignedto a SIF that is intended to prevent an event that would producecatastrophic community-wide consequences.

After a SIL is assigned to each SIF, each SIF is designed to operatewithin the designed average probability of failure on demand (PFD) thatcorresponds to the SIL assigned to the SIF. Because a SIF is typicallycomprised of a collection of instrumented function components (e.g., alogic solver, sensors, and actuators), and each of the instrumentedfunction components have a respective average PFD, which affects theoverall average PFD of the SIF, a designer has some flexibility in theway the overall average PFD is achieved. For example, by assuming a setof environmental conditions (e.g., humidity, temperature and pressure)that the instrumented function components will operate under, a designeris able to arrive at an overall average PFD by establishing regimentedtesting schedule for each of the instrumented function components.

Thus, once a SIS is commissioned, a plant engineer is able to estimatethe SIL level of a particular SIF as long as the actual maintenance andenvironmental conditions do not vary from the assumed design conditions.

Unfortunately, after a SIS is operational, a plant engineer is unable todetermine what the average PFD or SIL levels are for a SIF once actualtesting varies from the regimented test schedule. Furthermore, theactual PFD and SIL levels will vary depending upon actual environmentconditions, and as a consequence, a plant engineer will face furtheruncertainty as to what the actual PFD and SIL level is for the SIF.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the presentinvention will be more apparent from the following more particulardescription thereof, presented in conjunction with the followingdrawings wherein:

FIG. 1 is a is a block diagram of an exemplary industrial system inwhich a safety and reliability monitoring system according to oneembodiment of the present invention is implemented;

FIG. 2 is a flow chart illustrating steps carried out by the safety andreliability monitoring system of FIG. 1 according to several embodimentsof the present invention;

FIG. 3 is a is a graph depicting the relationship between safetyintegrity level and probability of failure on demand;

FIG. 4 is a is a graph, which depicts a range of values which aninstantaneous probability of failure on demand traverses during a periodof time for two different test intervals;

FIG. 5 depicts an industrial system in which another embodiment of thesafety and reliability monitoring system is implemented;

FIG. 6 depicts one embodiment of the safety controller of FIG. 5 inaccordance with one embodiment of the present invention;

FIG. 7 depicts an industrial system in which the safety and reliabilitymonitoring system is centrally operated according to one embodiment ofthe present invention;

FIG. 7A depicts one embodiment of the COSIL™ module of FIG. 7; and

FIG. 8 is one embodiment of a system computer that may be implemented tocarry out the functions of the system computers of FIGS. 5 and 7.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings.

SUMMARY OF THE INVENTION

In one embodiment, the invention may be characterized as a method, andmeans for accomplishing the method, for managing a safety instrumentedfunction including a plurality of instrumented function components, themethod including: obtaining operating information about at least one ofa plurality of instrumented function components; determining aprobability of failure on demand for the safety instrumented functionbased on the operating information; comparing the probability of failureon demand with a designed probability of failure on demand for thesafety instrumented function to establish a variance; and managing theplurality of instrumented function components based on the variance.

In another embodiment, the invention may be characterized as method forgenerating instantaneous safety availability information relating to aninstrumented function, the method including: receiving a time of a testperformed on an instrumented function component of the instrumentedfunction; determining an elapsed time between the time of the test and aparticular time; and calculating the safety availability information forthe instrumented function based on the elapsed time.

In a further embodiment, the invention may be characterized as a methodfor generating information pertinent to management of a safetyinstrumented function comprising: receiving, over a period of time, testinformation for instrumented function components in the safetyinstrumented function; calculating, as a function of the testinformation, a plurality of probability of failure on demand values,wherein each of the probability of failure on demand values represents aprobability of failure on demand of the safety instrumented function ata different point in time within the period of time; and generatingdisplay information representative of the plurality of probability offailure on demand values.

In yet another embodiment, the invention may be characterized ascomputer-executable code to generate safety availability information foran instrumented function, the code comprising instructions for:obtaining operating information about at least one of a plurality ofinstrumented function components, wherein the instrumented functionincludes the plurality of instrumented function components; determininga probability of failure on demand for the instrumented function basedon the operating information; generating the safety availabilityinformation based on the probability of failure on demand; and providingthe safety availability information to the personnel.

In yet a further embodiment, the invention may be characterized as aprocessor readable medium having instructions stored thereon forexecution by the processor to perform a method for providing, topersonnel, safety availability information for a plurality ofinstrumented functions, the method comprising: receiving safetyavailability information about an instrumented function wherein thesafety availability information is selected from the group consisting ofa probability of failure on demand, a safety integrity level and a riskreduction factor; generating a graphical user interface incorporatingthe safety availability information; and providing the graphical userinterface to a display.

DETAILED DESCRIPTION

In one aspect, the present invention is directed to a safety andreliability monitoring system, also referred to herein as a COSIL™system, which provides historical, real time and predictive probabilityfailures for an online instrumented system, e.g., a safety instrumentedsystem (SIS), based on events which occur during operation andmaintenance of the instrumented system.

Unlike current approaches for evaluating safety and reliability, whichare generally based upon static offline calculations using assumedaverage conditions over the life cycle of the instrumented system, thepresent invention according to several embodiments is capable ofproviding dynamic, online calculations of average probability of failureon demand, instantaneous probability of failure on demand, and safetyintegrity level (SIL) using actual events (e.g. time of test) in anindustrial plant. In some embodiments, the present invention alsoprovides reliability information (e.g., mean time to fail (MTTF)) basedon actual events. As a consequence, the inventive COSIL™ system may beemployed to provide accurate continuous online status information for aninstrumented function, e.g., a safety instrumented function.

The term continuous as used herein should not necessarily be construedto mean that calculations are continually performed (i.e., withoutinterruption). The COSIL™ system according to several embodiments,however, does allow a plant engineer to obtain substantially continuousvalues of PFD, SIL and/or MTTF, if so desired. It should be recognizedthat the COSIL™ system also allows calculations to be performed at lessfrequent intervals, e.g., daily, weekly or monthly.

Referring first to FIG. 1 shown is a block diagram of an exemplaryindustrial system 100 in which a COSIL™ system according to oneembodiment of the present invention is implemented. As shown, the system100 includes a programmable device 102 in communication, via a testinput 104, with an actuator 108 and a sensor 110 which implement aninstrumented function 112, e.g., a safety instrumented function (SIF).Also shown is an environmental input 106 which may be implemented toprovide additional input to the COSIL™ module 114.

The programmable device 102 may be realized using any one of a varietyof devices, which have input/output (I/O) functionality and contain aCPU and memory and (not shown). The programmable device 102 may be, forexample and without limitation, an intelligent field device, a safetycontroller, a programmable logic controller (PLC), a controller, ageneral purpose computer, a personal digital assistant (PDA) orpotentially any other device that includes a processor, memory andinput/output capability.

The instrumented function 112 represents a specific function executed bythe 108 actuator and sensor 110 to achieve or maintain a safe state fora process with respect to a specific event, e.g., a hazardous event.

The sensor 110 and actuator 108, also referred to herein as instrumentedfunction components, respectively monitor and react to processconditions in the industrial system 100 in order to help ensure that theinstrumented function 112 is carried out on demand. Although one sensor110 and one actuator 108 are shown for simplicity, it should berecognized that there are potentially multiple actuators and sensorsassociated with a particular instrumented function, e.g., a particularsafety instrumented function (SIF).

One of ordinary skill in the art will recognize that there are severalvarieties of both sensors and actuators. In one embodiment, for example,the sensor 110 is a pressure sensor and the actuator 108 controls a shutoff valve.

The test input portion 104 in some embodiments is an automated testinput unit, that provides test information, e.g., a most recent testtime and date, for the actuator 108 and/or sensor 110 to the COSIL™module 114 without human intervention. In one embodiment, for example,the actuator 108 and sensor 110 are coupled to the programmable device102 via a communication link. In other embodiments, the test inputportion 104 is a keypad or other user interface device, which allows aplant engineer, for example, to provide test information for theactuator 108 and/or sensor 110 to the programmable device 102.

Within the programmable device 102 are shown the COSIL™ module 114 andan I/O module 116. The COSIL™ module 114 according to severalembodiments is implemented by software that is read from a memory andprocessed by a CPU (not shown) of the programmable device 102. TheCOSIL™ module 114 generally comprises processor-executable code (a“COSIL™ program”) specifically designed to calculate, as a function ofoperating information for the instrumented function components 108, 110,a probability that the instrumented function 112 will fail on demand.

As discussed further herein, the COSIL™ program may be created by one ofseveral quantitative risk/reliability analysis (QRA) methodologiesincluding, but not limited to, function block diagram analysis, faulttree analysis, structured text techniques, simple equation methodology,Markov modeling and reliability block diagram methodology.

While referring to FIG. 1, simultaneous reference will be made to FIG.2, which is a flow chart 200 illustrating steps carried out by theCOSIL™ module 114 according to several embodiments of the presentinvention.

In operation, the COSIL™ module 114 initially obtains operatinginformation about at least one of the instrumented function components108, 110 (Step 201). In several embodiments the operating informationincludes test information that includes for example, a time and datewhen a test is successfully performed. In the present embodiment, theCOSIL™ module 114 receives the operating information via the testinformation input portion 104. In some embodiments, this testinformation is saved in a memory of the programmable device 102, whichallows the COSIL™ program to calculate an elapsed time between the timeof the test and a present (or future) time. In other embodiments, atimer is triggered that tracks the elapsed time between the time of thetest and a present time.

Although certainly not required, the operating information received atStep 201 may include environmental information, which characterizes theoperating environment for the instrumented function components 108, 110(e.g., humidity, temperature and pressure). In this way, the COSIL™module 114 is provided with actual environmental conditions for theinstrumented function components 108, 110 in the instrumented function112.

It should be recognized that various modes of operation of the COSIL™module 114 are contemplated in which, for example, only test informationis received, only environmental information is received, or both testand environmental information are received at the COSIL™ module 114. Itis also further contemplated that in one embodiment, both test andenvironmental information are received at the COSIL™ module 114, but theCOSIL™ module 114 only utilizes either the test or environmentalinformation.

Although the COSIL™ module 114 has been described as receiving test datafor one of the instrumented function components 108, 110 in theinstrumented function 112, it should be recognized that in severalembodiments, the COSIL™ module 114 receives test information on anongoing (e.g., substantially continuous) basis for potentially hundredsof instrumented function components, and is able to establish an elapsedtime since a last test for each of the hundreds of instrumented functioncomponents.

Once the COSIL™ module 114 has received the operating information aboutat least one of the instrumented function components 108, 110, theCOSIL™ module 114 calculates a probability of failure on demand (PFD)for the instrumented function 112 based on the operating information(Step 202). Although operating information for one or more of theinstrumented function components 108, 110 may be received at any giventime, it should be recognized that the PFD for the instrumented function112 is calculated as a function of a PFD for each of the instrumentedfunction components 108, 110 that contribute to the availability of theinstrumented function 112 on demand.

In some embodiments, the probability of failure on demand calculated inStep 202 is an instantaneous probability of failure on demand, which iscalculated using the following equation:PFD _(INST)=1−e ^(−λt)  Eq. (1)where λ is the failure rate for the element measured in a number offailures per unit of time and t is the elapsed time since the last testof the element. The failure rate λ, and hence PFD_(INST), will betypically be a function of environmental conditions such as temperature,pressure and humidity.

In other embodiments, the probability of failure on demand determined inStep 202 is an average probability of failure on demand, which iscalculated using the following equation:PFD _(AVG)=1+[(e ^(−λt)−1)/λt]  Eq. (2)where, again, λ is the failure rate for the element measured in a numberof failures per unit of time and t is the elapsed time since the lasttest of the instrumented function component. In yet other embodiments,the COSIL™ module 114 calculates both PFD_(INST) and PFD_(AVG) for theinstrumented function 112.

Although the PFD for the instrumented function 112 is calculated as afunction of the PFD of each of the instrumented function components 108,110, it should be recognized that the PFD for each of the instrumentedfunction components 108, 110 need not be calculated. For example, if oneof the instrumented function components 108, 110 has failed (i.e., theinstrumented function 112 is in a state of degraded operation), in oneembodiment the PFD value for the failed instrumented function componentis forced to a predefined value (e.g., 1.0). In this way, a PFD for theinstrumented function 112 may be calculated even though one of theinstrumented function components 108, 110 has failed.

For example, assume an instrumented function includes two instrumentedfunction components “a” and “b,” and the instrumented function fails ondemand if both “a” and “b” fail on demand. In non-degraded operation,the probability of failure on demand for the instrumented function is aproduct of the probability that “a” will fail on demand and theprobability that “b” will fail on demand (i.e., P=Pa*Pb). If “a” fails atest, however, then Pa is set equal to 1.0, and the probability that theinstrumented function will fail on demand during such degraded operationis P=1*Pb=Pb.

After a probability of failure on demand is calculated for theinstrumented function 112 (Step 202), the probability of failure ondemand is compared with a designed probability of failure on demand forthe instrumented function to establish a variance (Step 204). In oneembodiment, the variance is simply the difference (potentially positiveor negative) between the designed probability of failure on demand andthe calculated probability of failure on demand.

In some embodiments, the designed probability of demand is a designedaverage probability of failure on demand. As previously discussed,during a design phase of instrumented functions, e.g., safetyinstrumented functions, a designer typically establishes a test intervalperiod for each instrumented function component in an instrumentedfunction in order to ensure that an average PFD for the instrumentedfunction is maintained below a designed average PFD level.

In other embodiments, the designed probability of failure on demand is adesigned instantaneous probability of failure on demand, and the actualinstantaneous probability of failure on demand calculated in Step 202 iscompared with the designed instantaneous probability of failure ondemand.

Next, after a variance is established, the instrumented functioncomponents 108, 110 are managed based upon the variance. In oneembodiment for example, an alarm is provided when the calculatedprobability of failure on demand for an instrumented function exceeds adesigned probability of failure on demand. In the embodiments where thecalculated PFD_(AVG) is calculated, for example, an alarm is producedwhen the calculated PFD_(AVG) exceeds the designed average probabilityof failure on demand.

In other embodiments, as described further herein, in addition to alarmfeedback, the COSIL™ module 114 provides historical, on-line andpredictive reporting of probability of failure on demand values forseveral instrumented functions. Again, it should be recognized that theCOSIL™ system according to several embodiments tracks test information(and in some embodiments environmental conditions) for severalinstrumented function components within each of the instrumentedfunctions to arrive at a calculated probability of failure on demand foreach respective instrumented function. As a consequence of this wealthof information, a plant engineer is provided with many more managementoptions than prior plant management methodologies.

For example, it is often advantageous to perform tests, albeit outsideof the prescheduled test regimen, on instrumented function componentswhile a portion of a plant process is shut down for repairs. Testing oneor more instrumented function components 108, 110 in the instrumentedfunction 112 before their respective scheduled test dates, however,decreases the probability of failure on demand (PFD) and increases therisk reduction factor (RRF) for the associated instrumented function.Because the present invention, according to several embodiments,provides feedback indicating a resulting probability of failure ondemand due to the unscheduled testing, a plant engineer is able tomanage both the tested instrumented function components in theinstrumented function and other instrumented function components thatwere not tested based upon the unscheduled testing.

For example, if the calculated PFD_(AVG) after the unscheduled testingis reduced substantially below a designed average probability of failureon demand, instead of shutting a process down (and losing productivity)to test other instrumented function components according to theirdesigned schedule, a plant engineer may wait, e.g., until a plannedshutdown, with the knowledge that the PFD_(AVG) for the instrumentedfunction is still below the designed probability of failure on demand.Thus, the present embodiment allows a plant engineer to take credit fortesting in advance of a scheduled test date, and potentially save asubstantial amount of money by keeping a process running longer thanwould otherwise be possible using prior methodologies.

Similarly, in one embodiment the present invention allows a plantengineer to establish a risk if testing of an instrumented functioncomponent was not performed as scheduled. This is a significantadvantage over prior management methodologies, which leave a plantengineer unsure of whether the actual PFD_(AVG) or PFD_(INST) levelexceeds a designed PFD level.

Furthermore, in several embodiments the present invention allows a plantengineer to take credit for replacement of instrumented functioncomponents. Prior methodologies, which merely establish a fixed testschedule to maintain an acceptable PFD and risk reduction factor (RRF),simply do not provide the means for a plant engineer to take intoconsideration the effects of replacing several instrumented functioncomponents at different times. The present invention according to theseseveral embodiments, however, is able to track both replacement ofinstrumented function components and variances between actual testingand a designed test schedule to allow a plant engineer to take creditfor any increased risk reduction factor (RRF).

Yet another advantage of some embodiments of the present invention isthe ability to establish PFD_(AVG) or PFD_(INST) as a function ofenvironmental conditions including, e.g., temperature, pressure and/orhumidity. In these embodiments, a plant engineer may adjust the testinterval or environmental conditions to maintain a PFD_(AVG) orPFD_(INST) in response to varying environmental conditions. In contrast,a plant engineer operating under prior management methodologies cannottell what effect changes in environmental conditions have on the actualaverage PFD for any instrumented function. As discussed, prior plantmanagement methodologies included a predetermined testing schedule thatassumed a set of environmental conditions.

In some embodiments, the calculated probability of failure on demandvalues (i.e., PFD_(INST) and/or PFD_(AVG)), for safety instrumentedfunctions are converted to safety integrity levels. Referring to FIG. 3for example, shown is a graph depicting the relationship between safetyintegrity level and probability of failure on demand. As shown, therelationship is determined by the following equation:SIL=−Log(PFD)  Eq. (3)

Consequently, based on the on-line calculation of the PFD_(AvG) and/orPFD_(INST), a corresponding PFD_(AVG) and/or SIL_(INST) may becalculated as a real number. Thus, a plant engineer is able to monitorcalculated SIL values over time and deduce trends based upon the changesin the SIL level over time. For example, if continuous online SIL levelsof 3.3, 3.2, and 3.1 have been respectively calculated over threeprevious months, a plant engineer is able to determine that the SILlevel is about to change from a SIL 3 to a SIL 2, and the plant engineeris able to take action to raise or maintain the SIL level.

It should be recognized that in the context of a safety system, thepresent invention in several embodiments is applicable to both PFD/SILcalculations based on continuous (high demand) mode of operation and lowdemand operation.

Although online calculation of average probability of failure on demandPFD_(AVG) for an instrumented function provides a wealth of informationheretofore unavailable to a plant engineer, the ability to calculate aninstantaneous probability of failure on demand PFD_(INST) provides evenmore information to a plant engineer. An average probability of failureon demand, for example, does not provide information about the range ofprobability of failure on demand values that an instrumented functionmay render during a period that the PFD_(AVG) is determined.

Referring next to FIG. 4, shown is a graph depicting the probability offailure on demand for an instrumented function with respect to time fortwo different test intervals. Shown is a first graph 402 of aninstantaneous probability of failure on demand for an instrumentedfunction tested with an interval TI₁. Also shown is a second graph 404of an instantaneous probability of failure on demand for the sameinstrumented function, which is tested at an interval TI₂.

Although the test interval TI₁ produces an average probability offailure on demand (PFD_(avg)TI₁) which is below a designed averageprobability of failure on demand (Designed PFD_(avg)), there aresignificant periods of time during which the actual probability offailure on demand exceeds a designed average probability of failure ondemand (Designed PFD_(avg)). This graph indicates that a plant engineerwithout instantaneous PFD information may erroneously be led to believethat the instrumented function is providing a continuous risk reductionfactor (RRF), when in fact it is not.

By providing instantaneous probability of failure on demand informationto a plant engineer, the plant engineer is able to recognize potentialproblems, e.g., when the instantaneous PFD exceeds a designed maximum,and make adjustments to test intervals and/or environmental conditionsto bring the PFD and RRF of the instrumented function into an acceptablerange.

As shown in FIG. 4, by decreasing the test interval to TI₂ for example,the instantaneous probability of failure on demand 404 for theinstrumented function at all times is maintained below the designedaverage probability of failure on demand (Designed PFD_(avg)).

Referring next to FIG. 5, shown is an industrial system or plant 500 inwhich another embodiment of the COSIL™ system is implemented. As shown,coupled to a network 502 are several programmable devices 102A through102G including a DCS system 102A, a safety controller 102B, twointelligent field devices 102C, 102D coupled by a field bus 520, aprogrammable logic controller (PLC) 102E, a controller 102F and acontrol computer 102G. As shown, within each of the programmable devicesis a respective COSIL™ module 114A through 114G. Also shown coupled tothe network 502 are a system computer 510 and a personal digitalassistant 512.

In the present embodiment, each of the programmable devices 102A-102Gare coupled to instrumented function components (not shown) thatimplement one or more instrumented functions, e.g., safety instrumentedfunctions. The programmable devices 102A-102G are also coupled via thenetwork 502 to a system computer 510 and a personal digital assistant512. Although the programmable devices 102A-102G are able to communicatewith the system computer 510 and the personal digital assistant (PDA)512 via the network 502, it should be recognized that the programmabledevices 102A-102G do not necessarily communicate with each other.

One of ordinary skill in the art will recognize that a variety ofnetwork systems may be implemented to provide a communication pathbetween each of the programmable devices 102A-102G and the systemcomputer 510 and/or the personal digital assistant (PDA) 512. A wirelessnetwork, for example, may be utilized as part or all of the network 502.

In the present embodiment, each of the programmable devices 102A-102Gincludes a respective COSIL™ module 114A-114G for calculating aPFD_(INST) and/or a PFD_(AVG) for each of their respective instrumentedfunctions. It should be recognized that some of the programmable devices102A-102G may receive operating information from more than oneinstrumented function. For example, each of the programmable devices102A-102G may be associated with more than one instrumented function,and each instrumented function may include more than one instrumentedfunction component.

In operation, each programmable device 102A-102G, and hence, eachrespective COSIL™ module 114A-114G receives operating information, e.g.,test and/or environmental information, about its associated instrumentedfunction components, and calculates a probability of failure on demandfor the instrumented function associated with the instrumented functioncomponents.

In this embodiment, the calculated probability of failure on demand forone or more instrumented functions is forwarded via the network 502 tothe system computer 510 where it is provided by a reporting application516 to the display 514. As discussed further herein, informationincluding a designed SIL level, an on-line SIL level and instantaneousPFD as well as deviation lights/alarms may be displayed on the display514.

As previously discussed, the probability of failure on demand may beconverted to a SIL level for convenient reporting to a user at thesystem computer 510 and/or the personal digital assistant 512. One ofordinary skill in the art will recognize that conversion from aprobability of failure on demand to a SIL level may be calculated eitherin the programmable devices 102A-102G (e.g., in the respective COSIL™modules 114A-114G) or the system computer 510.

In one embodiment, calculated probability of failure on demand valuesfor each instrumented function are forwarded to the personal digitalassistant (PDA) 512 (e.g., via a wireless link). The personal digitalassistant 512 may be any portable computing device with programming andreporting capability including, but not limited to, cellular telephonesand notebook computers. The portable aspect of the PDA allows a plantmanager to receive alarms and/or generate reports without being “tied”to a desktop-type computer.

Referring next to FIG. 6, shown is one embodiment of the safetycontroller 102B of FIG. 5 in accordance with one embodiment of thepresent invention. As shown in FIG. 6, the safety controller 602includes a COSIL™ module 604 located within a control programs portion606 of the safety controller 602 and is in communication with a tester608 to receive information about testing of instrumented functioncomponents in a plant 600. Also shown is an environmental input, whichmay be utilized along with the information about testing to calculate anaverage probability of failure and/or an instantaneous probability offailure on demand for an instrumented function based upon the test andenvironmental information.

In some embodiments, the tester 608 is an operator that inputs testinformation manually into the safety controller 602, and in otherembodiments, the tester 608 is an automated test feedback device thatupdates the COSIL™ module 604 automatically with any test information.

As depicted in FIG. 6, the safety controller 602 provides an alarm 609to an operator 610 without communicating via the network 502. In oneembodiment, for example, the safety controller 602 does not communicateany PFD or SIL information to other devices and simply provides an alarmif any instrumented functions have a PFD level that rises above adesigned PFD level.

Referring next to FIG. 7, shown is an industrial system 700 in which theCOSIL™ system is centrally operated according to one embodiment of thepresent invention. As shown in FIG. 7, the present embodiment includes acollection of programmable devices 702, 704, 706, 708, 710, 712, 714,which include the same type of programmable devices described withreference to FIG. 5, but in the present embodiment, a system computer716 calculates PFD information for each of the safety instrumentedfunctions and provides, via a display 718, PFD and/or SIL informationfor each of the instrumented functions.

It should be recognized that each of the programmable devices isassociated with an instrumented function (e.g., the instrumentedfunction 112), and each instrumented function includes instrumentedfunction components (e.g., the instrumented function components 108,110). For clarity, however, the associated instrumented functions andinstrumented function components are not shown.

Referring briefly to FIG. 7A, shown is the COSIL™ module 720 of FIG. 7according to one embodiment. As shown, the COSIL™ module 720 includes Nseparate COSIL™ programs 722 ₁-722 _(N) that correspond to N respectiveinstrumented functions in the plant 700. In one embodiment, each of theprogrammable devices 702, 704, 706, 708, 710, 712, 714 forwardsoperating information (e.g., test information) to the system computer716 and/or the PDA 724 about each of the instrumented functioncomponents that the programmable device is associated with. In anotherembodiment, operating information (e.g., test information) aboutinstrumented function components is provided to the system computer 716by manual entry of a user (e.g., as tests are performed).

Each of the COSIL™ programs 722 ₁-722 _(N) in the COSIL™ module 720 isassociated with a corresponding one of N instrumented functions andtracks operating information for each instrumented function component(e.g., each of the instrumented function components 108, 110) in thecorresponding instrumented function (e.g., the instrumented function112). Based on the operating information, each of the COSIL™ programs722 ₁-722 _(N) calculates, on an ongoing basis, the probability offailure on demand for the corresponding one of the N instrumentedfunctions. In this way, the system computer 716 is able to providealarms responsive to actual plant events and/or conditions. As discussedherein, the COSIL™ module 720 in some embodiments also includeshistorical and predictive reporting capabilities in addition to on-linereporting.

Referring back to FIG. 7, the COSIL™ module 722 in an exemplaryembodiment is implemented in a personal digital assistant (PDA) 724. Inthis embodiment, the COSIL™ module 722 operates in much the same way asthe COSIL™ module 720 in the system computer 716, i.e., the COSIL™module 722 tracks operating information for each instrumented functioncomponent in each instrumented function and calculates, on an ongoingbasis, the probability of failure on demand for each monitoredinstrumented function. In addition, the COSIL™ module 722 may generatealarms and reports for a user, but this is not required.

Referring next to FIG. 8, shown is one embodiment of a system computer800 that may be implemented to carry out the functions of the systemcomputers 510, 716 of FIGS. 5 and 7.

As shown, the system computer 800 includes a quantitativerisk/reliability analysis (QRA) portion 802, which converts informationabout each instrumented function into one corresponding COSIL™ program.As discussed, each COSIL™ program (which may be stored in the memory804, the COSIL™ module 720 of the system computer 716, the COSIL™ module722 the PDA 724 and/or in the COSIL™ modules 114A-114G of theprogrammable devices 102A-102G) provides a PFD value for an associatedinstrumented function (e.g., the instrumented function 112) based onoperating information about instrumented function components (e.g., theinstrumented function components 108, 110) included in the instrumentedfunction.

In an exemplary embodiment, the QRA portion 802 utilizes function blockdiagram analysis that allows a user to convert an instrumented functionfault tree into a function block diagram. The QRA portion 802 thenconverts the function block diagram into a COSIL™ program for theinstrumented function. In one embodiment, the QRA portion 802 isimplemented with a Triconex® TS1131 application, but this is certainlynot required.

In one embodiment, to provide assistance to a user converting a faulttree to a function block diagram, the user is provided with one or moreelectronic files which include a library of function blocks, e.g. ANDand OR logic function blocks, along with Eq. (1) and Eq. (2) set forthabove. Such function blocks and equations may be tailored to be read andutilized by various QRA software applications including the Triconex®TS1131 application. In addition, in some embodiments, exemplary functionblock diagrams are provided to the user to further guide the user.

In other embodiments, other QRA methodologies are utilized to createCOSIL™ programs for each instrumented function including, but notlimited to, structured text techniques, simple equation methodology,Markov modeling and reliability block diagram methodology.

It should be recognized that the QRA portion 802 need not be implementedin the system computer 800, and in other embodiments, the COSIL™programs are created by the user on other machines, or simply providedto the user (e.g., from a third party).

In some embodiments (e.g., when the system computer 800 is implementedwithin the system 700 described with reference to FIG. 7), each COSIL™program is stored in a memory 804 of the system computer and a CPUcarries out the instructions in the COSIL™ program to calculate a PFDfor each instrumented function. In these embodiments, an input/output(I/O) portion 806 receives (e.g., from the network 726) operatinginformation for instrumented function components in each instrumentedfunction.

In other embodiments (e.g., when the system computer 800 is implementedin the system 500 described with reference to FIG. 5), after a COSIL™program is created for an instrumented function, it is provided (e.g.,uploaded via the network 502), to a programmable device (e.g., one ofthe programmable devices 102A-102G) where it is stored and carried outby a CPU on the programmable device. In these embodiments, the I/Oportion 806 receives PFD and/or SIL information from programmabledevices (e.g., the programmable devices 102A-102G) for instrumentedfunctions that are associated with each programmable device. In oneembodiment, Foundation Fieldbus function blocks may be uploaded alongwith the COSIL™ programs to the COSIL™ modules 114C, 114D of theintelligent filed devices 102C, 102D (which are compatible with theFoundation Fieldbus protocol).

In yet other embodiments, COSIL™ programs are stored in one or moreprogrammable devices in addition to the system computer 800. Thus,implementations that combine aspects of each of the systems 500, 700described with reference to FIGS. 5 and 7 are well within the scope ofthe present invention.

Also shown in the system computer 800 is a COSIL™ application 808. Inseveral embodiments the COSIL™ application includes code to produce agraphical user interface on the display 810, which provides userfeedback and user controls (e.g., icons) that allow a user to requestseveral variations of reports for the instrumented functions. Forexample, information including design SIL levels, continuous PFD and/orSIL levels and instantaneous PFD levels may be displayed for eachinstrumented function on an ongoing basis. Moreover, alarm informationis provided via the display for each instrumented function.

In an exemplary embodiment, the COSIL™ application 808 allows a user toanalyze historical and future probabilities of failure for eachinstrumented function in addition to on-line PFD information. Historicaloperating information for historical analysis may be stored in thememory 804, or may gathered based on retained records (e.g., testrecords). Beneficially, such historical analysis may be used toreconstruct what the PFD levels were at the time of a prior event. Forexample, if a plant experienced a boiler explosion, a historicalanalysis may be performed to determine PFD levels for instrumentedfunctions associated with the boiler. Such historical analysis mayprovide probative information during an accident investigation of suchan event.

The COSIL™ application 808 also allows a user to predict future PFD andor SIL levels. For example, a user is able to enter a hypotheticalscenario, which includes a future date and a set of assumed conditions(e.g., assumed test intervals and/or environmental conditions). Basedupon the information provided by the user, the COSIL™ application 808calculates PFD and/or SIL values for the instrumented function for thefuture date based upon the assumed conditions. This functionality allowsa plant engineer to test various potential courses of action and make aninformed decision based on the results provided by the COSIL™application 808.

Moreover, the COSIL™ application 808 allows future PFD and/or SIL levelsto be predicted based upon historical PFD information. Specifically, theCOSIL™ application according to one embodiment, tracks and reports PFDand/or SIL level changes for each instrumented function over a period oftime. Based upon the tracked information, trends may be establishedallowing a user to predict when an instrumented function is about todrop below a designed SIL level. As discussed, SIL levels may bereported as real numbers to allow small changes in SIL levels to beperceived by the user.

Also shown is an asset management application 812, which according to anexemplary embodiment both receives information from the COSIL™application 808 and provides information to the COSIL™ application 808.Specifically, the asset management application 812 tracks replacement ofinstrumented function components, and when an instrumented functioncomponent is replaced, the asset management application 812 informs theCOSIL™ application 808. In this way, the COSIL™ application 808 is ableto update the COSIL™ program that is associated with the replacedinstrumented function component. In turn, the COSIL™ program resets theelapsed time associated with the instrumented function component asthough a test were just performed on the replaced instrumented functioncomponent.

Conversely, when a test is performed on an instrumented functioncomponent, the COSIL™ application 808 receives test informationindicating whether the test was successful or not and provides the assetmanagement application 812 with the test information. In this way theasset management application 812 is provided up to date statusinformation for instrumented function components.

It should be recognized that information between the asset managementapplication 812 and the COSIL™ application 808 may be transferredaccording to various techniques. For example, each application 808, 812may be configured to communicate according to the other application'sspecific application program interface (API). Alternatively, theapplications 808, 812 may exchange information according to well-knowncommunication formats (e.g., using extensible markup language (XML)).

It should also be recognized that the asset management application 812may be located remotely from the system computer 800 and communicatewith the COSIL™ application 808 via a network connection.

While the invention herein disclosed has been described by means ofspecific embodiments and applications thereof, numerous modificationsand variations could be made thereto by those skilled in the art withoutdeparting from the scope of the invention set forth in the claims.

For example, the present invention is readily adaptable to providingonline mean time to failure (MTTF) information for an instrumentedfunction. As one of ordinary skill in the art will appreciate, thequantitative risk/reliability (QRA) methodologies utilized to provide aCOSIL™ program may be modified so that the COSIL™ program calculatesMTTF values instead of probability of failure on demand (PFD) values.Although testing intervals are typically not part of an MTTFcalculation, it is contemplated that operating information includingnotice of a failure of an instrumented function component will beutilized in such a calculation.

Although instrumented function components are typically replaced quicklyupon failure, knowledge of the MTTF value while an instrumented functioncomponent is nonfunctional provides a plant engineer with information tomake a more informed decision about operating the instrumented functionuntil the instrumented function component is replaced.

1. A method for managing a safety instrumented function including aplurality of instrumented function components, the method comprising:obtaining operating information about at least one of the plurality ofinstrumented function components; determining a probability of failureon demand for the safety instrumented function based on the operatinginformation; comparing the probability of failure on demand with adesigned probability of failure on demand for the safety instrumentedfunction to establish a variance; and managing the plurality ofinstrumented function components based on the variance.
 2. The method ofclaim 1 wherein the probability of failure on demand is an instantaneousprobability of failure on demand.
 3. The method of claim 1 wherein theprobability of failure on demand is an average probability of failure ondemand.
 4. The method of claim 1 wherein the obtaining operatinginformation comprises obtaining a test completion time for the at leastone of the plurality of instrumented function components.
 5. The methodof claim 4 wherein the test completion time is a future test completiontime, and wherein the determining the probability of failure on demandis performed before the future test completion time.
 6. The method ofclaim 1 wherein the obtaining operating information includes obtainingan indication that the at least one of the plurality of instrumentedfunction components has failed.
 7. The method of claim 6 including:setting a probability of failure on demand for the at least one of theplurality of instrumented function components to a predefined value;wherein the determining includes calculating the probability of failureon demand for the safety instrumented function as a function of theprobability of failure on demand for the at least one of the pluralityof instrumented function components.
 8. The method of claim 1 whereinthe obtaining further includes: obtaining operating information abouteach of the plurality of instrumented function components; wherein thedetermining includes calculating probability of failure on demand foreach of the plurality of instrumented function components as a functionof corresponding operating information received for each of theplurality of instrumented function components, thereby generating aplurality of probability of failure on demand values; and wherein theprobability of failure on demand for the safety instrumented function isdetermined as a function of the plurality of probability of failure ondemand values.
 9. The method of claim 7 wherein the obtaininginformation comprises obtaining environmental operating information. 10.The method of claim 9 wherein the environmental operating informationincludes information selected from the group consisting of: temperatureinformation, pressure information and humidity information.
 11. Themethod of claim 1 wherein the managing comprises reducing a testinterval between tests of the at least one of a plurality ofinstrumented function components in response to the variance exceeding amaximum variance.
 12. The method of claim 1 wherein the managingcomprises reducing a test interval between tests of another of theplurality of instrumented function components in response to thevariance exceeding a maximum variance.
 13. A method for generatinginstantaneous safety availability information relating to aninstrumented function, the method comprising: receiving a time of a testperformed on an instrumented function component of the instrumentedfunction; determining an elapsed time between the time of the test and aparticular time; and calculating the instantaneous safety availabilityinformation for the instrumented function based on the elapsed time. 14.The method of claim 13, wherein the instrumented function component isselected from the group consisting of a sensor and an actuator.
 15. Themethod of claim 14, wherein the instantaneous safety availabilityinformation is an instantaneous safety integrity level.
 16. The methodof claim 13, wherein the instantaneous safety availability informationis the instantaneous probability of failure on demand.
 17. The method ofclaim 13, including: providing the instantaneous safety availabilityinformation to a display viewable by personnel managing the instrumentedfunction.
 18. A method for generating information pertinent tomanagement of a safety instrumented function comprising: receiving, overa period of time, test information for instrumented function componentsin the safety instrumented function; calculating, as a function of thetest information, a plurality of probability of failure on demandvalues, wherein each of the probability of failure on demand valuesrepresents a probability of failure on demand of the safety instrumentedfunction at a different point in time within the period of time; andgenerating display information representative of the plurality ofprobability of failure on demand values.
 19. The method of claim 18wherein the generating further comprises: converting each of theplurality of probability of failure on demand values to a safetyintegrity level represented as a real number, thereby producing aplurality of safety integrity levels represented as real numbers;wherein the display information representative of the plurality ofprobability of failure on demand values includes the plurality of safetyintegrity levels represented as real numbers.
 20. The method of claim 19further comprising: graphically displaying the plurality of safetyintegrity levels represented as real numbers, thereby providing anindication of a safety integrity level trend for the safety instrumentedfunction.
 21. A system for managing a safety instrumented functionincluding a plurality of instrumented function components, the systemcomprising: means for obtaining operating information about at least oneof the plurality of instrumented function components; means fordetermining a probability of failure on demand for the safetyinstrumented function based on the operating information; means forcomparing the probability of failure on demand with a designedprobability of failure on demand for the safety instrumented function toestablish a variance; and means for providing, based on the variance,information useable for managing the plurality of instrumented functioncomponents.
 22. The system of claim 21, wherein the probability offailure on demand is an instantaneous probability of failure on demand.23. The system of claim 21, wherein the probability of failure on demandis an average probability of failure on demand.
 24. The system of claim21, wherein the means for obtaining information comprises means forobtaining a test completion time for the at least one of a plurality ofinstrumented function components.
 25. The system of claim 24, whereinthe test completion time is a future test completion time, wherein themeans for determining the probability of failure on demand includesmeans for determining the probability of failure on demand before thefuture test completion time.
 26. The system of claim 24 wherein themeans for obtaining information comprises means for obtainingenvironmental operating information.
 27. The system of claim 26, whereinthe environmental operating information includes information selectedfrom the group consisting of: temperature information, pressureinformation and humidity information.
 28. Computer-executable code togenerate safety availability information for an instrumented function,the code comprising instructions for: obtaining operating informationabout at least one of a plurality of instrumented function components,wherein the instrumented function includes the plurality of instrumentedfunction components; determining a probability of failure on demand forthe instrumented function based on the operating information; andgenerating the safety availability information based on the probabilityof failure on demand.
 29. The computer-executable code of claim 28wherein the determining includes: determining a probability of failureon demand for each of the a plurality of instrumented functioncomponents thereby generating a plurality of probability on demandvalues; and calculating the probability of failure on demand for theinstrumented function based on the plurality of probability on demandvalues.
 30. The computer-executable code of claim 28 wherein theprobability of failure on demand is an instantaneous probability offailure on demand.
 31. The computer-executable code of claim 28 whereinthe probability of failure on demand is an average probability offailure on demand.
 32. The computer-executable code of claim 28 whereinthe obtaining operating information comprises obtaining a testcompletion time for the at least one of the plurality of instrumentedfunction components.
 33. The computer-executable code of claim 28further including instructions for providing an alarm based on thesafety availability information.
 34. The computer-executable code ofclaim 28 further including instructions for providing a display of thesafety availability information.
 35. The computer-executable code ofclaim 28 wherein the safety availability information is selected fromthe group consisting of: a probability of failure on demand, a safetyintegrity level and a risk reduction factor.
 36. The computer-executablecode of claim 28 wherein the obtaining includes obtaining, via anetwork, operating information about the at least one of the pluralityof instrumented function components from a programmable device coupledto the at least one of the plurality of instrumented functioncomponents.
 37. A processor readable medium having instructions storedthereon for execution by the processor to perform a method forproviding, to personnel, safety availability information for a pluralityof instrumented functions, the method comprising: receiving safetyavailability information about an instrumented function wherein thesafety availability information is selected from the group consisting ofa probability of failure on demand, a safety integrity level and a riskreduction factor; generating a graphical user interface incorporatingthe safety availability information; and providing the graphical userinterface to a display.
 38. The processor readable medium of claim 37wherein the receiving includes receiving, via a network connection, thesafety availability information about an instrumented function from aprogrammable device; wherein the programmable device is coupled to aplurality of safety instrumented function components; wherein theprogrammable device calculates a probability of failure on demand foreach of the plurality of safety instrumented components, therebygenerating a plurality of probability of failure on demand values;wherein the programmable device determines safety availabilityinformation as a function of the plurality of probability of failure ondemand values.
 39. The processor readable medium of claim 37 wherein thereceiving includes receiving the safety availability information aboutan instrumented function from a memory of a system computer wherein thesystem computer houses the processor.
 40. A method for managing aninstrumented function including a plurality of instrumented functioncomponents comprising: obtaining operating information about at leastone of the plurality of instrumented function components; determining amean time to failure for the instrumented function based on theoperating information; comparing the mean time to failure with adesigned mean time to failure for the instrumented function to establisha variance; and managing the plurality of devices based on the variance.41. The method of claim 40 wherein the operating information includesinformation about a failure of the at least one of the plurality ofinstrumented function components.